Abstract

As manufacturing technology has been moving to the stage of full automation over the years, one of the fundamental requirements is the ability to accurately predict the output performance of machining processes. The focus of present study is to predict surface roughness using the surface temperature of a turning workpiece with the aid of an infrared temperature sensor. Relationship between the workpiece surface temperature and the cutting parameters and also between the surface roughness and cutting parameters were found out for indirect measurement of surface roughness through the surface temperature of the workpiece, and then correlate these temperatures to the surface roughness. A 33 full factorial design was used in order to get the output data uniformly distributed all over the ranges of the input parameters. Regression equations to get the relation between different response variables (Surface roughness and workpiece surface temperature) and the input parameters (speed, feed, and depth of cut) were found out using statistical analysis software. The experimental results show that the workpiece surface temperature can be sensed and used effectively as an indicator of the cutting performance. Thus, it is possible to increase machine utilization and decrease production cost in an automated manufacturing environment.

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